Electronic torque wrench

ABSTRACT

A torque wrench for use in driving fasteners is provided. The wrench includes an electronics unit disposed within a housing engaged with the body of the wrench that is capable of sensing and measuring the torque applied to a fastener by the wrench and providing an output of the level of torque to the user. The data sensed by the electronics unit can be utilized to provide feedback to the user regarding the operation of the wrench, and to monitor the overall operation of the wrench for calibration purposes, among other functions. During use, the wrench can provide the user with visual, audible and tactile feedback regarding the operation of the device relative to stored maximum torque values stored in the electronics unit. The housing for the electronics unit can be formed to be a single use component of the tool or can be designed for multiple uses with a configuration that can be engaged with cradles forming the body of the wrench having various different configurations.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. Non-Provisional patentapplication Ser. No. 15/153,024, filed on May 12, 2016, which is acontinuation of U.S. Non-Provisional patent application Ser. No.14/091,023, filed on Nov. 26, 2013, now U.S. Pat. No. 9,358,672, issuedJun. 7, 2016, which is a continuation-in part of U.S. Non-Provisionalpatent application Ser. No. 13/915,395, filed on Jun. 11, 2013, now U.S.Pat. No. 8,714,058, issued May 6, 2014, and claims benefit of U.S.Provisional Application No. 61/784,396, filed Mar. 14, 2013 and claimsbenefit of U.S. Provisional Application No. 61/729,918, filed Nov. 26,2012, and said U.S. Non-Provisional patent application Ser. No.13/915,395 filed Jun. 11, 2013 is a continuation of U.S. Non-Provisionalpatent application Ser. No. 13/110,446, filed May 18, 2011, now U.S.Pat. No. 8,485,075, issued Jul. 16, 103, which claims benefit of U.S.Provisional Application No. 61/345,817, filed May 18, 2010, the entiretyof which are each expressly incorporated by reference herein.

FIELD OF THE INVENTION

The present invention relates to tools, and more specifically to toolsincluding electronic measuring and display device for providingindication of the forces being applied by the tools.

BACKGROUND OF THE INVENTION

Often, fasteners used to assemble performance critical components aretightened to a specified torque level to introduce a “pretension” in thefastener. As torque is applied to the head of the fastener, beyond acertain level of torque the fastener begins to stretch. This stretchresults in the pretension in the fastener which then holds thecomponents together. A popular method of tightening these fasteners isto use a torque wrench. Accurate and reliable torque wrenches helpinsure the fasteners are tightened to the proper torque specifications.

Torque wrenches vary from simple mechanical types to sophisticatedelectronic types. Mechanical type torque wrenches are generally lessexpensive than electronic ones. There are two common types of mechanicaltorque wrenches, beam and clicker types. With a beam type torque wrench,a beam bends relative to a non-deflecting beam in response to the torquebeing applied with the wrench. The amount of deflection of the bendingbeam relative to the non-deflecting beam indicates the amount of torqueapplied to the fastener. Clicker type torque wrenches work by preloadinga snap mechanism with a spring to release at a specified torque, therebygenerating a click noise. Other types of mechanical torque wrenchesinclude indicating, ratcheting, torque limiting, in-line and beam stylesof torque wrenches. In an indicating wrench, torque value is measuredand displayed on a scale. In a torque limiting wrench, the wrench willdrive the fastener until a preset torque value is reached at which pointthe wrench will slip and cease to transmit the torque applied. In aratcheting mechanism wrench, in order to drive a fastener into asubstrate such as wood or bone it is necessary to rotate the fastenerthrough multiple rotations about its axis. For a hand held tool, inorder to drive fasteners, typically the user will have to change theirgrip or change hands in order to keep driving the fastener due to thelimitation of the range of motion of the bones joint in a human hand,which occurs at approximately 100 to 180 degrees depending on theperson. A ratcheting mechanism in a fastener driver tool allows the userto rotate the instrument in the opposite direction to the torque beingapplied without lifting or otherwise disengaging the device driving bitfrom the fastener and without lifting the hand off the device orchanging hands. With a ratcheting mechanism in the tool the user canrotate the tool and drive the fastener through as many degrees ofrotation as their hand allows and then ratchet the driving tool in theopposite direction so as to be able to drive the fastener through asmany degrees without lifting the hand off the driving tool.

Electronic torque wrenches (ETWs) tend to be more expensive thanmechanical torque wrenches, and more accurate as well. When applyingtorque to a fastener with an electronic torque wrench, the torquereadings indicated on the display device of the electronic torque wrenchin a visible manner, such as by a numeric or light indication, and areproportional to the pretension in the fastener due to the appliedtorque. However, the readings also depend on, among other factors, theunder head friction between the head of the fastener and the adjacentsurface of the component and the friction between the mating threads.Static friction is greater than dynamic friction. Therefore, whentorquing operations are initiated, increased amounts of torque may berequired to overcome static friction forces and initiate rotation of thefastener. Therefore, it follows that torque is preferably applied to thefastener in a slow and continuous manner to allow friction forces tostabilize, to help insure accuracy and to help prevent over-torquing,which can result in damage being done to the fastener or the substrate,with extreme cases resulting in destruction of the fastener orsubstrate. As well, it is often desirable for the user to see both thecurrent torque value (torque being applied at that instant) and the peaktorque value (maximum torque applied up to the present instant)simultaneously. However, existing torque wrenches typically display onlythe current torque value or the peak torque value at any given time.

When a torque wrench is operated in a “tracking mode,” the currenttorque value is displayed and the user therefore does not necessarilyget immediate feedback regarding the actual peak torque value to whichthe fastener may have been subjected. Although with some electronictorque wrenches it is possible to get this information by downloadingthe data, this action is typically not instantaneous and, therefore, theoperator does not get immediate feedback. On the other hand, whenoperating in a “peak hold mode,” the display of the electronic torquewrench typically shows only the maximum torque applied to the fastenerup to that time. In the peak hold mode, the user is often ignorant ofthe current torque level, which can lead to either over orunder-torquing the fastener.

Another factor that can affect the accuracy of a reading on anelectronic torque wrench is the operating temperature. Strain gages thatare used in electronic torque wrenches to measure applied torque areoften affected by temperature. Therefore, to obtain accurate torquemeasurements, it is often necessary to measure the existing temperatureand adjust the displayed torque value for a given strain gauge reading.

Regardless of which type ETW is used, torque extensions may be requiredto tighten fasteners that are in locations that the torque wrench willnot reach. One of the most common methods of attaching a torqueextension to an ETW is to replace the original drive head with anextension that has its own drive head. Once the extension is inserted,the readings of the ETW must usually be corrected for any change inlever arm length due to the extension. With the extension in place, theactual torque experienced by the fastener will be either higher or lowerthan what is actually displayed on the ETW, depending on whether theextension extends outwardly or inwardly from the end of the ETW,respectively.

For each different length extension, a different correction factor mustbe calculated. Typically, the end user calculates a correction factorand either divides or multiplies the desired final actual torque valueto be applied to the fastener by this correction factor to determine thefinal compensated set torque value (as displayed by the ETW) that is tobe input into the ETW. Whether the actual torque value is divided by ormultiplied by the correction factor is dependent upon the method ofdetermining the correction factor. The final compensated set torquevalue is the value at which, when displayed, the user ceases to applytorque to the fastener. Typically, the user will only know the finalcompensated set torque value accurately and is not able to accuratelydetermine the intermediate torque values. In other words, the user onlycalculates the final compensated set torque value for the set torque andwill not be able to continuously monitor the actual torque values duringtorquing operations as only “compensated” values are displayed by theETW. This situation can lead to over and under-torquing, possiblyresulting in loss of performance of the fasteners.

Further, with regard to prior art electronic torque wrenches, theapplications of each of these types of wrenches are normally withinenvironments where the cleanliness of the wrench is not an issue, suchas in automotive repair shops. As such, the ability of the prior artelectronic torque wrench to be cleaned to a sterile level is not arequirement for the construction of the electronic torque wrench, andcorrespondingly the design and construction of these prior art wrenchesis not capable of protecting the internal electronic components of thesetypes of wrenches to enable the electronic torque wrenches to beutilized in environments where the wrench is required to be sterilizedprior to use.

Thus, it is desirable to develop an electronic torque wrench that iscapable of withstanding the temperatures and pressures required tosterilize the device in order to protect the internal components of thedevice. Alternatively, it is desirable to develop an electronic torquewrench capable of being operated in a sterile environment that can besterilized and that includes one or more disposable components that areoperably connectable to the wrench for operation of the wrench but thatdo not require sterilization after their initial use.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, an electronic torquewrench is provided for engaging a workpiece in a sterile environment,the electronic torque wrench including a wrench body with a wrench headdisposed on the wrench body, wherein the wrench head is configured toengage the workpiece. A grip handle is disposed on the wrench bodyopposite the wrench head and a user interface is carried by the wrenchbody which is also connected to a microprocessor disposed within thehandle, or optionally at a location spaced from the handle. In oneembodiment, the user interface includes a display with a first readoutand a second readout, and an input device for inputting a preset torquevalue, all of which are operably connected to the microprocessor. Thefirst readout displays a peak torque value continuously duringoperations and the second readout displays an applied torque valuecontinuously during operations.

According to another aspect of the present invention, a method isprovided of displaying a peak torque value and an applied torque valueas a percentage of a preset torque value on a display of an electronictorque wrench during a torquing operation on a workpiece in a sterileenvironment. The method includes one or more of the steps of: inputtingthe preset torque value into the electronic torque wrench, the presettorque value being the maximum torque that is desired to be applied tothe workpiece; detecting a current torque being applied to theworkpiece; comparing the current torque to an existing peak torque valuedisplayed on the display; displaying the current torque on the digitaldisplay as the peak torque value when the current torque exceeds thedisplayed peak torque value; comparing the current torque to the presettorque value to determine a percentage of the preset torque value thatthe current torque corresponds to; and displaying the percentage on thedisplay such that the percentage and the peak torque value are displayedsimultaneously at all times during the torquing operation.

According to still another aspect of the present invention, anelectronic torque wrench for driving a workpiece in a sterileenvironment is provided in which the torque wrench includes a wrenchbody having a handle end and a wrench head receiving end. A wrench headincludes a workpiece receiving end and a mounting end that is removablyreceived by the wrench head receiving end of the wrench body. A wrenchhead sensing device is carried by the wrench head receiving end andincludes an electrical connection between the wrench head sensing deviceand the microprocessor so that the wrench head sensing device can sendan electrical signal to the microprocessor indicating the presence ofthe wrench head on the wrench head receiving end.

According to still another aspect of the present invention, anelectronic torque wrench is provided with torque adjustment capability,display of desired torque settings, actual torque achieved display,torque measuring capability and optionally a shutoff at a predeterminedtorque level. The electronic torque wrench provides repeatable andaccurate torque application without regard to operator capability withina sterile operating environment.

Among the several features, objects and advantages of the presentinvention are the provision of an improved torque-applying wrench which:

-   -   measures applied torque precisely by electronically sensing        torque during operation;    -   allows convenient operator selection of the predetermined torque        level and displays the predetermined torque level;    -   does not require external sensing and control circuits but are        instead integrated completely into the tool in a manner that        enables the wrench to be utilized in a sterile environment;    -   provides for torque sensing and torque control by electronic        feedback;    -   does not require an external source of electrical power but is        instead capable of long-term use solely under battery power;    -   can be integrated into typical configurations of existing torque        wrenches by use of sensing and control elements which will not        interfere with normal speed and convenience of operation of the        torque wrench;    -   uses a torque-sensing technology of such significant economy and        relative simplicity as to make possible portable digital        torque-responsive, and optionally torque-controlling wrenches;        and    -   provides such torque-responsive, and optionally        torque-controlling tools with such economy and simplicity as to        be suited for medical use in sterile environments, as well as        use in many other technical areas.

The present disclosure relates to an electronic torque wrench apparatus,system associated with the apparatus, and method of using the apparatusand the system for use in attaching fasteners and other tool operationsin a sterile medical environment. Securing the fastening components at adesired torque setting allows for secure attachment of the componentsand any structures related thereto without under-tightening orover-tightening the components. Under-tightening the components couldresult in disengagement of the components. Over-tightening thecomponents could make disengaging the components difficult or couldcause damage to the components. To prevent under-tightening orover-tightening a torque measurement can be made while tightening thecomponents, to meet a target torque setting or to apply a torque withina desired torque range.

According to still a further aspect of the present invention, anelectronic torque wrench apparatus, system, and method of using theapparatus and system is provided for tightening and standardizing theforces associated with a fastener system for medical procedures. In oneembodiment, the system includes access to a database of fastenerconfiguration information for various medical procedures, specificallyas they relate to the particular individual on which the procedure is tobe performed. Information is provided from the database to the wrenchapparatus. The wrench apparatus provides verification of the informationand verification of application of the information by the use of thewrench. After use, the wrench assembly transfers the information back tothe system to provide a historical record of the procedure and thetorque values applied by the physician using the wrench to therespective fasteners.

According to still another aspect of the present invention, theelectronic torque wrench assembly includes a coupling device or couplerand the wrench. The coupling device receives information from the systemand transfers it to the wrench. Once the fastener configurationinformation is received, the wrench is removed from the coupler and isused to establish torque settings for use in the fastener torqueprocess. Verification of the tightening process is recorded at thewrench during use and transmitted back to the coupler. The coupler thentransfers the information to the system.

According to still a further aspect of the present invention, the systemincludes a driving device management server which communicates with themicroprocessor. The coupler is connected to the server to collectinformation about the procedure/subject from the server. The devicemanagement server then delivers corresponding fastener configurationinformation to the coupler for transfer to the electronic torque wrench.The wrench utilizes the information in the fastener tightening processto alert the physician of the proper torque value for the particularfastener being tightened in the procedure. Verification of theinformation can be recorded at and/or by the wrench and transferred backto the coupler when the wrench is placed in the coupler. Informationtransferred to the coupler can be transmitted to the proceduremanagement server for verification, transaction completion and storage.

According to still another aspect of the present invention, the dataregarding the use of the torque wrench in performing the fastenertightening procedure or process stored in the microprocessor can betransferred to the coupler and/or server to record the usage of thewrench. This data can be stored in the server for use in determining thenecessary calibration for the wrench, based on various parameters suchas the number of uses of the wrench, and the overall length of time ofuse of the wrench, among others.

According to still a further aspect of the present invention, the wrenchcan be configured to include a cradle. The cradle includes a slot,aperture or other suitable opening for the insertion of a powerpack/sensor module that includes the electronic torque sensing deviceand is adapted to be engaged with the desired driving instrument orimplement. The power pack/sensor module mates with the cradle toactivate the power pack/sensor module, which is pre-calibrated andoperable to provide feedback to the individual utilizing the toolregarding the level of torque being applied by the wrench.

According to still another aspect of the present invention, the powerpack/sensor module can be designed to be pre-calibrated for accuratedetermination of the torque applied to a fastener in a single use, suchthat the power pack/sensor module can be disposed of after use in asingle procedure or process.

According to another aspect of the present disclosure, the powerpack/sensor module and cradle include lock out features that preventoperation of the power pack/sensor module when not properlyinterconnected. The power pack/sensor module can further be designedwith a configuration that interconnected with different cradles havingdifferent implements or configurations, allowing a single powerpack/sensor module to be engaged and/or utilized with multiple cradles.

According to still another aspect of the present invention, the cradleand/or the power pack/sensor module can be formed to be sterilizable,such that the cradle and/or the power pack/sensor module can be re-usedin multiple procedures.

Other aspects, features and advantages of the present invention will beset forth in part in the description which follows and the accompanyingdrawings, wherein the embodiments of the disclosure are described andshown, and in part will become apparent upon examination of thefollowing detailed description taken in conjunction with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings illustrate the best mode currently contemplated ofpracticing the present invention.

In the drawings:

FIG. 1 is an isometric view of a first embodiment of an electronicdriving tool constructed according to the present disclosure;

FIG. 2 is a cross-sectional view along line 2-2 of FIG. 1 ;

FIG. 3 is an exploded, isometric view of a second embodiment of anelectronic driving tool constructed according to the present disclosure;

FIG. 4 is an isometric view of the interior components of the tool ofFIG. 3 ;

FIG. 5 is an isometric view of a third embodiment of an electronicdriving tool constructed according to the present disclosure;

FIGS. 6 and 6A are isometric views of a lighting element utilized withthe tool of FIG. 1 ;

FIG. 7 is a cross-sectional view of power cell component of the tool ofFIG. 1 ;

FIG. 8 is a cross-sectional view of a temperature compensation bladderor use with the tool of FIG. 1 ;

FIG. 9 is an exploded, isometric view of a fourth embodiment of anelectronic driving tool constructed according to the present disclosure;

FIG. 10 is a cross-sectional view of a fifth embodiment of an electronicdriving tool constructed according to the present disclosure;

FIGS. 11A-11B are front plan views of the display for the tool of FIG. 1;

FIG. 12 is a schematic view of a first embodiment of an electronicssystem of the tool of FIG. 1 ;

FIG. 13 is a schematic view of a second embodiment of an electronicssystem of the tool of FIG. 1 ;

FIG. 14 is a schematic view of a first embodiment of the operatingfunctions of the tool of FIG. 1 ;

FIG. 15 is a schematic view of a second embodiment of the operatingfunctions of the tool of FIG. 1 ;

FIG. 16 is a schematic view illustrating the operation of the tool ofFIG. 1 ;

FIG. 17 is a schematic view of a medical suite including a sixthembodiment of an electronic driving tool constructed according to thepresent disclosure;

FIG. 18 is a schematic view of the tool of FIG. 17 ;

FIGS. 19A and 19B are schematic views illustrating the operation of thetool of FIG. 17 ;

FIG. 20 is a cross-sectional view of a seventh embodiment of anelectronic driving tool constructed according to the present disclosure;

FIG. 21 is a cross-sectional view of an eighth embodiment of anelectronic driving tool constructed according to the present disclosure;

FIG. 22 is an isometric view of a calibration tray used with theelectronic driving tool;

FIG. 23 is an isometric view of a driving tool constructed according tothe present disclosure utilized with the calibration tray of FIG. 22 ;

FIG. 24 is a partially broken away, isometric view of the calibrationtray of FIG. 22 ;

FIG. 25 is a front isometric view of a ninth embodiment of an electronicdriving tool constructed according to the present disclosure;

FIG. 26 is a front plan view of the tool of FIG. 25 ;

FIG. 27 is a rear isometric view of the tool of FIG. 25 ;

FIGS. 28A-28B are front plan views of a tenth embodiment of anelectronic driving tool constructed according to the present disclosure;

FIGS. 29A-29B are front plan views of an eleventh embodiment of anelectronic driving tool constructed according to the present disclosure;

FIG. 30 is an isometric view of a twelfth embodiment of an electronicdriving tool constructed according to the present disclosure;

FIG. 31 is a cross-sectional view of the tool of FIG. 30 ;

FIG. 32 is an isometric view of a locking member for a power source ofthe tool of FIG. 30 ;

FIG. 33 is a cross-sectional view of the locking member of FIG. 32 ;

FIG. 34 is a partially broken away, cross-sectional view of the tool ofFIG. 30 ;

FIG. 35 is an isometric view of the cradle of the tool of FIG. 30 ;

FIG. 36 is a cross-sectional view of a thirteenth embodiment of anelectronic driving tool constructed according to the present invention;

FIG. 37 is a front cross-sectional view of a fourteenth embodiment of anelectronic driving tool constructed according to the present invention;

FIG. 38 is a side cross-sectional view of the tool of FIG. 37 ;

FIG. 39 is a partially broken away, isometric view of a fifteenthembodiment of an electronic driving too constructed according to thepresent invention;

FIG. 40 is an isometric view of a sixteenth embodiment of an electronicdriving too constructed according to the present invention;

FIG. 41 is a partially broken away, isometric view of the tool of FIG.40 ;

FIG. 42 is a cross-sectional view along line 42-42 of FIG. 41 ;

FIG. 43 is an isometric view of a seventeenth embodiment of anelectronic driving too constructed according to the present invention;

FIG. 44 is a partially broken away, isometric view of the tool of FIG.43 ;

FIG. 45 is a cross-sectional view along line 45-45 of FIG. 43 ;

FIGS. 46A-46F are views of alternative configurations for the electronicdriving tool of FIG. 25 ;

FIGS. 47A-47D are front plan views of various tools showing a powerpack/sensor module with a single configuration engaged with cradleshaving different operating configurations;

FIG. 48 is an isometric view of a locking and fixed collar arrangementof the tool of FIG. 47A-47D;

FIG. 49 is an isometric view of an eighteenth embodiment of anelectronic driving too constructed according to the present invention;

FIG. 50 is a schematic view of a nineteenth embodiment of an electronicdriving tool constructed according to the present invention;

FIG. 51 is a schematic view of a twentieth embodiment of an electronicdriving tool constructed according to the present invention;

FIG. 52 is a an isometric view of a charging station for a driving toolconstructed according to the present invention;

FIG. 53 is an isometric view of a twenty-first embodiment of a drivingtool constructed for use with the charging station of FIG. 52 ;

FIG. 54 is an isometric view of the driving tool of FIG. 53 charging onthe charging station of FIG. 52 ;

FIG. 55 is an isometric view of a twenty-second embodiment of a drivingtool constructed according to the present invention;

FIG. 56 is a partially exploded view of the tool of FIG. 55 ;

FIG. 57 is a fully exploded view of the tool of FIG. 55 ;

FIG. 58 is a schematic view of a twenty-third embodiment of a drivingtool constructed according to the present invention; a FIGS. 59A-59E areschematic views of a display of the tool of FIG. 58 ;

FIG. 60 is an isometric view of an embodiment of the driving tool ofFIG. 55 in an open position for use with a non-sterile battery pack;

FIG. 61 is an isometric view of a sterile shield for use with the toolof FIG. 60 ;

FIG. 62 is an isometric view of the shield of FIG. 61 engaged with thetool of FIG. 60 ;

FIG. 63 is an isometric view of the insertion of the non-sterile batterypack into the tool of FIG. 60 through the shield of FIG. 61 ; and

FIG. 64 is an isometric view of the driving tool of FIG. 60 in a closedposition with the non-sterile battery pack retained therein.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to various embodiments of theinvention, one or more examples of which are illustrated in theaccompanying drawings. Each example is provided by way of explanation,not limitation, of the invention. In fact, it will be apparent to thoseskilled in the art that modifications and variations can be made in thepresent invention without departing from the scope and spirit thereof.For instance, features illustrated or described as part of oneembodiment may be used on another embodiment to yield a still furtherembodiment. Thus, it is intended that the present invention covers suchmodifications and variations as come within the scope of the appendedclaims and their equivalents.

Referring now to FIGS. 1 and 2 , an in-line electronic torque wrench 10in accordance with the present invention is shown. The electronic torquewrench 10 includes a wrench body 12, a ratchet/wrench shaft 14, aresilient grip handle 16, a housing 18, a battery assembly 19, and anelectronics unit 20 with a user interface or display 22. Preferably,wrench body 12 is of generally a tubular construction, and receivesshaft 14 at a first end and a power supply or battery assembly 19 at asecond end, secured therein by an end cap 17. Housing 18 is mountedtherebetween and carries electronics unit 20.

As shown, a front end 26 of shaft 14 includes an adapter 28 connected toa suitable ratcheting mechanism (not shown) such as that shown in U.S.Pat. No. 7,413,065, incorporated by reference herein in its entirety.The adapter 28 is configured to receive variously sized sockets,extensions, etc. The adapter 28 can also be detachably connected to theshaft 14 by any suitable mechanism.

The attachment mechanism for securing the shaft 14 to the body 12includes a sensor 30 configured to sense the torque or strain exerted bythe wrench 10 through the shaft 14 onto a fastener (not shown). Thesensor 30 can take any of a number of suitable forms, such as a straingauge, a Hall sensor, and a piezoelectric sensor, among others.

The sensor 30 is operably connected to the electronics unit 20, suchthat the signal generated by the sensor 30 can be transmitted to theunit 20. Once in the unit 20, the unit 20 can utilize the signal for avariety of purposes, such as to calculate a torque value from the signalto provide a real-time indication of the torque applied via the wrench10 on the display 22.

The operation of the electronics unit 20 and the sensor 30 is controlledby a switch 32 disposed on the body 12, and operably connected betweenthe unit 20 and sensor 30, and the power supply 19 at the opposite end.Thus, the switch 32 enables power to be selectively applied to the unit20 and sensor 30 as desired. The engagement of the housing 18, the body12 the handle 16 and the end cap 17 provide an enclosure or barrier 33,which can also be formed separately, for the battery assembly 19, theelectronics unit 20 and the sensor(s) 30 that enables the wrench 10 tobe autoclaved for sterilization purposes without damaging the batteryassembly 19, the electronics unit 20 or the sensor 30, as well as thedisplay 22.

Referring now to FIGS. 3 and 4 , a second embodiment of the wrench 10′is illustrated. In this embodiment, the wrench 10′ has a T-shape, withthe shaft 14′ extending perpendicularly from the body 12′. In theillustrated embodiment, the shaft 14′ is disposed centrally on the body12′, such that the power source 19′ and the electronics unit 20′ aredisposed on opposite sides of the body 12′ within the body 12′, suchthat the body 12′ provides an enclosure for the power source 19′ and theelectronics unit 20′ that enables the wrench 10′ to be autoclaved forsterilization purposes without damaging the battery assembly 19′ or theelectronics unit 20′. Alternatively, the shaft 14′ can be oriented toone side or the other of the body 12′, as desired.

The shaft 14′ can be connected directly to the body 12′ or to aratcheting mechanism (not shown) disposed within the body 12′. At theconnection of the shaft 14′ to the body 12′, a sensor 30′ is disposed todetermine the strain or torque being applied by the wrench 10′ throughthe shaft 14′ to a fastener or other substrate (not shown) forrepresentation on a suitable display (not shown) on the body 12′.

Referring now to FIG. 5 , a third embodiment of the wrench 110 isillustrated. The wrench 110 has a T-shape similar to the embodiment ofFIGS. 3 and 4 , but includes a piezoelectric sensor 130 located withinthe body 112. The sensor 130 is formed of a first element 132 on a flatsurface 133 of the shaft 114 and a second element 134 is disposed on anadjacent flat surface 135 of the body 112. The relative position of theelements 132 and 134 is determined by the electronics unit 120 disposedwithin the body 112, which is connected to the elements 132 and 134 byconductors 136 to receive signals from the elements 132 and 134.

Looking now at FIGS. 6 and 6A, a driving tool or wrench 210 is shown inwhich the wrench 210 includes a light source 250. The light source 250is formed with a generally circular housing 252 that has a centralaperture 254 that is slightly larger in shape than the shaft 214, suchthat the housing 252 is positionable around the shaft 214 eitherimmediately adjacent the body 212, or disposed within the body 212. Ineither configuration, the housing 252 includes a number of lightingelements 256 positioned thereon that are operably connected to the powersource 219 and optionally to the electronic unit 220 which arepositioned within the body 212, either directly or via an interveningmember, such as the housing 252 if formed of a conductive material. Thelighting elements 256 direct light downwardly from the body 212 alongand around the shaft 214 to illuminate the area immediately surroundingthe shaft 214, thereby providing a better viewing area for theindividual operating the wrench 210.

Referring now to FIG. 7 , a power source 319 of the wrench 10, 10′ isillustrated that includes a battery or power cell 360 positioned withina capsule 362 that is releasably engaged with a cap 364, such as via athreaded connection. The cap 364 is sealingly engaged with the capsule362 by a sealing member 366 disposed between the capsule 362 and the cap364. The power cell 360 is held within the capsule 366 by an insulatingmaterial 368 to prevent any inadvertent discharge of electricity fromthe power source 360 through the capsule 362. To facilitate the passageof power from the cell 360 to the wrench 10, 10′ when the capsule 362 isengaged with the body 12′ of the wrench 10, 10′, conductors (not shown)are disposed within the capsule 362 and connect the power cell 360 withor through the cap 364 to the electronics unit 20, 20′ disposed withinthe body 12, 12′ of the wrench 10, 10′.

In FIG. 8 , the wrench 10′ is shown as including an expandable bladder468 within the body 12′. The bladder 468 can expand or contract withinthe body 12′ as shown by the variations in size of the bladder shown by468 a, 468 b and 468 c in response to changes in the temperature orpressure of the environment in which the wrench 10′ is located, such aswhen autoclaved, to further maintain the proper operation of theinternal components of the wrench 10′, e.g., the power source 19′ andelectronics unit 20′, beyond the protection afforded by the body 12′ orbarrier 33.

Looking now at FIG. 9 , a fourth embodiment of the wrench 510 isillustrated. In the wrench 510, the body 512, in addition to theratcheting mechanism 515 and other components, such as the power sourceand electronics unit (not shown), has a pop-out torque level indicationmechanism 570, such as that disclosed in U.S. patent application Ser.No. 12/192,295, incorporated herein by reference in its entirety. Thepop-out indication mechanism 570 operates in conjunction with thedisplay 522 to illustrate the particular torque level at which thewrench 510 is being operated.

Referring now to FIG. 10 , a fifth embodiment of the wrench 610 isillustrated in which the wrench 610 is a deflection beam type wrench.The wrench 610 includes a body 612 within which the power source 619 andelectronic unit 620 are disposed. A sensor 630 operably connected to theelectronics unit 620 is disposed on a beam 672 engaged with the body612, and having an adapter 628 attached thereto opposite the body 612.The adapter 628 is operable engagable with the fastener via anattachment releasable secured to the adapter 628 in order to allow thewrench 610 to drive the fastener. The torque applied to the fastener bythe wrench 610 is measured by the electronics unit 620 via signalsreceived from the sensor 630 as a result of the deflection of the beam672.

Looking now at FIGS. 11A-13 , one embodiment of the display 22 for thewrench 10 is illustrated. The display 22 can take any suitable form, andcan be positioned on the exterior surface of the body 12 for interactionwith the individual utilizing the wrench 10, or can be disposed withinthe body 12 in an easily viewable location, such as under a transparentsection of the body. The display 22 provides various indications to theuser of the wrench 10 regarding the operation of the wrench 10, such as,but not limited to, the actual torque being applied in various units,the amount of torque being applied relative to preset maximum andminimum values, the power level remaining in the power source 19, andany error message with regard to the operation of the wrench 10, e.g., adefect in the operation of the electronic unit 20.

The display 22 can also include one or more user input devices 80disposed in the body 12. The devices 80 can include a power button 82, aunit selection button 84, increment/decrement buttons 86 a and 86 b, andthree light emitting diodes (LEDs) 88 a, 88 b and 88 c. In oneembodiment, the light emitting diodes 88 a, 88 b and 88 c are green,yellow and red, respectively, when activated in response to the torquelevels sensed by the electronics unit 20. Also, a speaker 90 for audiblesignals can also be disposed on the body 12. Additionally, though LEDs88 a-88 c and speaker 90 are shown, the wrench 10 may alternatively oradditionally include a device for creating tactile sensation such as avibration, heating, or cooling. Also, though one possible positioningfor the display 22 is shown in FIGS. 1 and 2 , other locations, such asat the end or underside of the body 12 are suitable as well.

Block diagram representations of the electronics of the wrench 10,including the display 22 and a microcontroller 92, showing variousinputs and outputs, are shown in FIGS. 12-13 . When electronic torquewrench 10 is used to apply and measure torque, the sensor 30, i.e., theHall sensor, the piezoelectric sensor, the strain gages of the straintensor, or other suitable sensing device, sense the torque applied tothe fastener and send a proportional electrical signal 794 to a signalconditioning unit 795 that amplifies the signal, adjusts for any offsetof the signal, and compensates the signal for the current temperatureusing temperature sensor 800 and conditioning circuit 802 and adjustingfor the offset of the signal increases the accuracy of the wrench bycompensating the signal for any reading that may be present beforetorque is actually applied to the fastener. An amplified and conditionedelectrical signal 796 is then fed to the microcontroller 92 thatconverts electrical signal 796 to an equivalent torque value in thedesired units. Microcontroller 92 sends an electrical signal 797including the current torque level value and the peak torque value tothe display 22, which can include a liquid crystal display (LCD) unit798, via an LCD driver circuit 799. In one embodiment, the display 22represents the current torque level value as a bar graph andsimultaneously displays the peak torque value as a numeric value, asseen in FIGS. 11A and 11B. Furthermore, microcontroller 92 generatesalarm signals in the form of one or more audio signals and/or lightdisplays of appropriate color once the current torque level value iswithin a pre-selected range of the preset limit torque value, that areused to operate the LEDs 88 a-88 c, and the speaker 90. The LEDs 88 a-88c coincide with the level of torque being applied relative to the presetmaximum torque level. When any of the LEDs 88 a-88 c are activated,either in a flashing or continuous manner, the user is alerted as to thelevel of torque being applied via the wrench 10, with the yellow and redLEDs 88 b and 88 c, along with the speaker 90 and any associatedvibration generator (not shown) indicating to the user that they areapproaching or at the torque level where they are over-torquing thefastener.

The switches or buttons 86 a-86 b are located on the body 12 adjacentthe display 22 and enable the user to adjust the parameters utilized bythe electronics unit 20 in setting the minimums and maximum torquelevels for the wrench 10.

In addition, the electronics unit 20 can include a memory component 800that is operably connected to the microprocessor or microcontroller 92in order to record the information received by the unit 92 during theoperation of the wrench 10. In one embodiment, torque values arereceived by microcontroller 92 on a continuous basis over controlledintervals, which may be specified, for example by the operator of wrench10 through a user interface, such as the buttons 86 a-86 b, or otherdevices that can be operably connected to the microprocessor 92. In anycase, in another embodiment, one or more torque measurement values areperiodically or continuously stored in memory 800 for later retrievaland/or processing.

FIGS. 11A-11B show detailed views of embodiments of digital displays 22that can be used in any of the embodiments of the wrench 10 of thepresent invention. The LCD units 798 include a current torque levelindicator, a four digit numeric display, an indication of units selected(foot-pound, inch-pound, and Newton-meter), a torque direction indicator(clockwise (CW) by default and counterclockwise (CCW) if selected), abattery level indicator, a peak hold (PH) indicator and an error (Err)indicator. As shown, current torque level indicator is in the form of abar graph. The bar graph is shown in two embodiments, horizontal andvertical. In either case, preferably, the bar graph includes a total often segments and a frame that encompasses all ten segments. The frame isfilled by the ten segments when the preset torque value input by theuser is reached. At other times, the frame is only partially filled withsegments, and therefore gives a graphical display of approximately howmuch torque is currently being applied and how much more torque needs tobe applied to the fastener to reach the preset torque valve.

As shown, two small arrows are located on opposing sides of the eighthsegment. The arrows are graphical indicators to the user that thecurrent torque level is above 75% of the preset torque value. Eachsegment within the frame represents 10% of the preset torque value,starting from the left or bottom of each bar graph, respectively. Forexample, if only the first two of segments are displayed, the currenttorque level is above 15% and below 24% of the preset torque value, andis therefore approximately 20% of the preset torque value.Simultaneously, the digital display also displays the peak torque valueapplied up until that time in the numeric display. As such, if torquehas been applied in a continuously increasing manner, the peak torquevalue displayed will actually be the same as the current torque value.The decimal point will be displayed depending on which units the userhas selected.

In use, the user, rather than focusing on four digit numeric display,views the bar graph of current torque level indicator until the appliedtorque level reaches approximately 75% to 80% of the preset torquevalue, depending on the user's comfort level when approaching the presettorque level. At this point, the user changes focus to the numericdisplay for a precise indication of the current torque being applied asthe preset torque value is approached. As discussed, the numeric displayshows the peak torque value to which the fastener has been subjected. Assuch, if the user has “backed off” during the application of torque, thevalue indicated on numeric display will not change until it is exceededby the current torque value. The display allows the user to apply torqueto the fastener and know both how much torque is currently applied andhow much more torque needs to be applied before reaching the targetpreset torque value.

Alternately, the bar graph display can be used for displaying the peaktorque value and the numeric display can be used to display the currenttorque value. Alternate embodiments include graphical displays otherthan the previously discussed bar graph, such as a pie chart display inwhich each of five segments represents approximately 20% of the presettorque value initially selected by the user, a circular dial-typedisplay in which each segment also represents approximately 20% of thepreset torque value, an indicator mark at approximately 80% of thepreset torque value, or a graphical display that is similar inappearance to a standard dial type analog display wherein a pointer, orneedle, indicates the percentage of the preset torque value beingapplied as it points to graduations positioned about the display. Note,although the number of segments and graduations are shown asrepresenting 20% of the preset torque value, the number may be alteredas necessary to indicate a different desired percentage of the presettorque value.

Referring now to FIG. 14-15 , the overall functionality of theelectronics unit 20 is graphically illustrated. In FIG. 14 , in itsgeneral functionality, the power supply 19 provides power to the circuitboard or electronics unit 20 which receives signals from the sensor 30for ultimate transmission to the display 22. In FIG. 15 , the variousfunctions of the electronics unit 20 are illustrated, namely, aninitialization/setup function 1000, a torque calibration function 1002,an angle calibration function 1004, a torque measurement function 1006,a torque and angle measuring function 1008, a sleep function 1010, andwake up function 1012, and an error function 1014.

In FIG. 16 , a flow chart 1500 of one embodiment of an algorithm usingany known and suitable method or system for electronically determiningthe torque applied by the wrench that can be used with the electronicsunit 20 of the various embodiments of the wrench 10, 2000, 4000, 5000,6000, 7000 of the present disclosure is shown. Prior to initiatingtorquing operations, a user inputs a preset torque value into theelectronic torque wrench that equals the maximum desired torque to beapplied to the fastener. This value is displayed in the display 22 untilthe user actually applies torque to the fastener, at which time thenumeric display switches to displaying the peak torque value. As torqueis applied, microcontroller 92 receives and reads a temperaturecompensated and signal conditioned analog voltage signal 796 from signalconditioning circuit 795, converts the analog signal to an equivalentdigital number, converts the digital number to an equivalent currenttorque value corresponding to the user selected units, and determineswhether the current torque value is a new peak torque value. This isaccomplished by comparing the current torque value to the existing peaktorque value, and either replacing the peak torque value if it isexceeded (T), or letting it remain if it is not (F). Once both thecurrent torque value and peak torque value are determined,microcontroller 92 sends electrical signal commands to LCD drivercircuit 799 to generate appropriate signals to display 22 for updatingthe readout shown in current torque level indicator and the peak torquevalue shown in display 22.

In addition, microcontroller 92 switches green 88 a, yellow 88 b, andred 88 c LEDs on or off depending on the peak torque value applied tothe fastener up until that time. Preferably, green LED 88 a comes on aslong as the peak torque value is below 75% of the preset torque valueand is switched off once the peak torque reaches 75% of the presettorque value. Yellow LED 88 b comes on for peak torque values greaterthan 75% but less than 99% of the preset torque value. Red LED 88 ccomes on once the peak torque value reaches 99% of the preset torquevalue and stays on thereafter. The selection of percentage ranges foreach color may be programmed, and the percentages at which the LEDs areswitched on or off can be changed to suit the specific application.Embodiments are envisioned that include a liquid crystal display devicethat is capable of displaying multiple colors. This permits the warningLEDs to be replaced by appropriately colored symbols on the LCD. Aswell, the segments of the bar graphs and graphical displays can be madeto have varying colors in order to enhance the warning capabilities forthe user.

Once the peak torque reaches the preset torque value, or is within auser selected range, microcontroller 92 generates electrical signals togenerate an alarm sound on speaker 90. A red color backlight (not shown)coincides with the audible alarm signal, indicating that the presettorque value has been reached. More colors can be added as backlights tofurther assist the user when approaching the preset torque value. Theuser is also alerted if the mechanically safe torque value (elasticlimit of the strain tensor) has been exceeded, possibly causing thetorque wrench to lose proper calibration. This is determined bycomparing the peak torque value to the elastic limit torque of thetorque wrench. If the safe torque value is exceeded (T), an “Err”message is displayed on error indicator and the unit stops, thusindicating that the electronic torque wrench unit needs calibrationbefore it can be used again.

As shown in FIGS. 17-18 , the wrench 10 can be configured for use in amedical suite 12000 to mate with a control unit 1100. Control unit 1100is configured to communicate with wrench 10 when wrench 10 is dockedtherein or otherwise engaged therewith. Control unit 1100 includecontrol unit display 1102, control unit buttons 1104 used for inputtingcommands and interfacing with menus presented on display 1102, anddocking section 1106. During docking, wrench 10 is inserted in dockingcavity 1108 defined by cradle 1110 and having a width dimension, alength dimension, and a depth dimension which are slightly larger than acorresponding length, width, and depth of body 12 to allow removablysecure positioning of wrench 10 within the docking cavity 1108. Acoupling or junction (not shown) is also provided along an interior wallof docking cavity 1108 for electrically connecting control unit 1100 tomicrocontroller 92 in the body 12. Connection between the control unit1100 and wrench 10 may also be via wireless communication when controlunit 1100 and wrench 10 are brought in close proximity.

Control units may also be commonly available portable digital assistantsor PDA such as those available from Palm, or other mobile computingdevices, including various tablet computers and smart phones, amongothers. Software configured to communicate with wrench 10 may be loadedonto the PDA which can use operating systems such as Palm OS, MicrosoftWindows CE, or other mobile computing device operating systems presentlyavailable or hereafter devised. The communications and operationsprotocols used by the tool may also be written in HTML or XMLprogramming language, or other suitable systems presently available orhereafter devised for interoperability with a wide range of software andhardware platforms.

The control unit 1100 can be in the form of an Ethernet cradle which issimilar to the cradle bundled with most hand held devices. However, suchan Ethernet cradle may be designed to include an Ethernet card and anRJ-45 connector. This connector allows the unit to connect to a localarea network via a CAT5 cable attached to a hub or switch. This willallow for rapid communication (10 Mbps, 100 MBps, or gigabit) betweenthe wrench 10 and a tool management system 1200.

FIGS. 19A-19B are simplified diagrammatic views of a tool managementsystem 1200. Tool management system 1200 can be configured on a generalpurpose computer that includes a processor 1202, a specificationdatabase module 1204 accessible by or loaded onto the system 1200, adatabase module 1206 accessible by or loaded onto system 1200, and acommunications port 1208. The modules 1204, 1206 can be accessed by theprocessor locally or remotely over a communications network such as alocal area network, wide area network, over an intranet, or over theInternet or another suitable communications hereafter devised and usablefor this system. Tool management system 1200 will also include bothdynamic memory such as RAM and a storage device such as a hard drive orthe like. The term “module” referenced in this disclosure is meant tobroadly cover various types of software code including but not limitedto routines, functions, objects, libraries, classes, members, packages,procedures, methods, or lines of code together performing similarfunctionality to these types of coding, therefore one program canoperate to provides the functionality, or the functionality can bedivided over a number of programs, accessible either locally orremotely. The system 1200 may also communicate with one or more outputdevices 1300 such as monitors or printers. For the purposes of thepresent example, and as illustrated in figures, the database modules1204, 1206 will be loaded on the tool management system 1200.

The tool management system 1200 can communicate directly with wrench 10.System 1200 and wrench 10 make up torque management system. Thisconnection may be via a hardwired or wireless using any of thecommunications protocols previously described. In an alternativeembodiment, the control unit 1200 can also be used an intermediateinterface between tool management system 1200 and wrench 10 to form thetorque management system 1400. The control unit 1100 can also be used tocontrol more than one wrench 10. Recall that wrench 10 removably dockswith control unit 1100 so one wrench 10 can be removed and anotherconnected so that one control unit 1100 can be used to communicate withmore than one wrench 10.

The general steps by which tool/torque management system 1200/1400 areused initially involve the identification of a torque application, canbe any task or process that requires the use of a torque tool whereprecise tolerances, a desired range, or limits of the magnitude of thetorque applied need to be monitored. Generally, a fastening orunfastening of a fastener to a member can be a torque application. Onespecific example of a torque application is related to inserting screwsinto a plate in a human body during a surgical procedure. In thisexample, a number of screws need to be inserted through the plate intobone in order to secure the plate where desired within the body, e.g.,to repair a break in a bone. It is known in the medical device/fastenerindustry that each manufacturer offers specifications for a recommendedand maximum safe amount of torque that should be applied to securelyfasten the screws.

Once selected, the information on the torque application is suppliedfrom a database 1204, 1206 on the system 1200 to the wrench 10, and/orto the control unit 1100. In doing so, the system 1200 references thespecifications database module 1206 to find corresponding manufacturer'sspecifications for the identified torque application. Alternatively, thefastener (not shown) can have a code used to identify the fastener withsystem 1200. The identification to the system 1200 can be made via thewrench 10, the system 1200, or the control unit 110 using any inputmethod or device including using a keyboard, interacting with agraphical user interface that has menus or other selection protocols,scanning a barcode, or from import/export or other communication withprocedure database.

Once identified, the manufacturer's specifications for the identifiedtorque application are retrieved to the wrench 10. If the system 1200referenced the specification database 1206, then the specifications aretransmitted from the system 1200 to the wrench 10 via a communicationspath. Alternatively, the system 1200 sends the specifications to thecontrol unit 1100 which in turn transmits the specifications to thewrench 10 when the wrench 10 is docked therein. If the specificationsare already on wrench 10, for example because the same torqueapplication was performed prior to the current torque application, thespecification can be recalled from the memory 800 of the wrench 10.Similarly, if the specifications are already resident on the controlunit 1100, the specifications can be recalled and loaded onto wrench 10.

After loading the specifications on the wrench 10, a user or operator,such as, for example, physician, uses the wrench 10 loaded with thetorque application specifications to perform the torque application. Thewrench 10 or the wrench 10-control unit 1100 combination are configuredto guide the user through the torque application. This guidance can comein the form of specifying a particular portion of the application anddisplaying a maximum allowable applied torque. The torque magnitudesdisplayed can be in either U.S. customary units (lbs-ft) or in S.I.units (N-m). The guidance can also come in the form of producing analert during torque application to notify the user that the user isapproaching or has exceeded a specification, such as the LEDs 88 a-88 c,the speaker 90 or other devices mentioned previously.

Generally simultaneously with the guidance process described above andthe various steps of the torque application, a torque sensing devicewithin the wrench 10 measures or captures data corresponding to theactual torque applied for that application. That information or data isstored in memory 800 within the wrench 10 or is immediately transmittedback to the control unit 1100 or directly to the tool management system1200. The data is used to create a record of exactly how much torque wasapplied during the various stages of the torque application, and howlong the wrench 10 was in use. In an embodiment where the data is notimmediately transmitted from the wrench 10, the data can be retrievedand sent to the control unit 1100 and system 1200 during docking.

The specifications and other torque-related information in thespecifications database module 1204 can be compiled from promulgatedindustry standards or from specification released by original equipmentmanufacturers. For example, factory torque specifications developed bythe device manufacturer relating to the proper torque for tightening thefasteners can be maintained in the database 1204. The information can bemodified, updated and corrected as necessary. If this system 1200 isconnected to a network that has access to updated specifications, thisinformation update can occur at generally any time of the day.

This information recorded by the system 1200 can be used to determinethe number of uses of a particular wrench or tool, such that the system1200 can inform the user that the tool must be replaced or that acomponent of the tool, such as a power/sensor pack 2004 (FIG. 25 ) needsto be discarded and replaced. The system 1200, when incorporated atleast partially into the pack 2004 can provide an indication to the userof the current status of the tool, such as how long in terms of minutesor hours, or how many uses the tool or component thereof has left priorto the need for replacement.

In addition, surgical torque wrenches and similar surgical devices arerecommended to be sent back to the factory for calibration after aperiod of time which is usually six months to a year since date ofmanufacture. However, in reality these wrenches are sometimes notchecked to ensure they are calibrated or properly maintained. In thetool 2000 as shown in FIG. 26 , the tool 2000 can have sensors or otherelectronic components on or within the tool 2000 that keep track of theusage and age of the tool 2000 to help make the device smarter andinform the user when it is time to send the tool 2000 for service andcalibration. Some examples of these types of sensors to be used alone orin combination with one another include:

-   -   1. A thermal sensor and counter type circuit (not shown) can be        employed within the tool 2000, such as in conjunction with the        electronics unit 20, to count the number of autoclave cycles and        alarm or otherwise notify the user when the preprogrammed number        of cycles has been reached that the tool 2000 needs to be        serviced or have its calibration checked, such as via the        display 22, 6000, 6002.    -   2. A sensor (not shown) used in conjunction with the electronics        unit 20 can count the number of actuations of the tool 2000 and        notify the user via the display 22, 6000, 6002 when the        preprogrammed number of actuations has been reached that the        tool 2000 needs to be serviced or have its calibration checked.    -   3. Electronic components like real-time clocks can be employed        in conjunction with the electronics unit 20 to keep track of        time the tool 2000 has been in the field since date of its        manufacture. The clock can be programmed to send out a signal or        message to notify the user, such as via the display 22, 6000,        6002, that it is time for the tool 2000 to be calibrated or        serviced. The clock could be reset or reprogrammed for the next        calibration interval after the calibration service has been        performed.

Alternatively, the tool 2000 can be supplied with a counter and anelectronic storage medium or memory device (not shown) within the tool2000 in conjunction with the electronics unit 20 to give an indicationof how much time the tool 2000 has been in use. This information that issensed and/or stored by the tool 2000 can include

-   -   1. How many times the tool 2000 has been autoclaved or    -   2. The number of times the tool 2000 had been actuated.    -   3. The torque values that have been applied, especially when the        tool 2000 has been torqued excessively.    -   4. The age of the tool 2000 since date of manufacture.

This information is stored in the electronic memory medium 800 in thetool 2000 or in a separate electronic storage location (not shown)operably connected to the tool 2000 directly or wirelessly, and thisdata could be retrieved at any time by simply scanning the tool 2000with a scanner. In the case of tools 2000 with a screen 6000, the tool2000 could display a message or alarm on the screen to inform the userwhen it is time to send the tool 2000 for calibration or service oradvise the user how much life is left on the tool 2000.

In order to maintain system integrity and security, the various stepsand/or operations described above may include password systemimplementation or user authentication for added security and useraccountability. For example, a physician performing a torque applicationmay have to enter a worker ID. As another example, specificationsupdates to the specification database module 1204 may require managerlevel access.

Looking now at FIG. 20 , a seventh embodiment of the present inventionis illustrated in which the electronic torque wrench 10″ includes awrench body 12″, a ratchet/wrench shaft 14″, and a battery assembly 19″,and an electronics unit 20″ with a user interface or display 22″disposed within a suitable barrier 33″ formed by or within the body 12″and engaged with a sensor 30″ on the shaft 14″. A torque limitingmechanism 50″, such as that disclosed in U.S. Pat. No. 7,430,945, whichexpressly is incorporated herein by reference in its entirety, isdisposed within and at one end 52″ of the wrench body 12″, and aratcheting mechanism 54″ is located opposite the mechanism 50″, withboth mechanisms 50″ and 54″ operably connected to the shaft 14″.

Referring now to FIG. 21 , an eighth embodiment of the present inventionis illustrated where the wrench 10″′ has a T-shape, with the shaft 14″′extending perpendicularly from the body 12″′. In the illustratedembodiment, the shaft 14″′ is disposed centrally on the body 12″′, suchthat the battery assembly or power source 19″′ and the electronics unit20″′ disposed within a suitable barrier 33″ formed by or within the body12′″ and operably connected to the shaft 14″′ via the sensor 30″′ aredisposed around the shaft 14″′ within a housing 21′″ connected to andextending perpendicularly from the body 12″′. The housing 21″′ isconnected to the body 12″′ and the shaft 14″′ can be connected directlyto the body 12″′ or to a torque limiting mechanism 50″′, such as thatdisclosed in U.S. Pat. No. 7,430,945, which expressly is incorporatedherein by reference in its entirety, disposed within the body 12″′. Inaddition, the disposed at least partially within the housing 21″′ and inconnection with the shaft 14″′ is a ratcheting mechanism 54″′ aspreviously described with regard to the embodiment of FIGS. 1 and 2 .Further, in this, or any other embodiment of the wrench 10 the wrenchcan include a ratcheting mechanism 54, a mechanical torque limitingmechanism 50, or a mechanical torque measuring mechanism, such as themechanical torque level measuring and/or indication mechanism 570, orany combination thereof in addition to the other components of anydisclosed embodiment of the electronic torque wrench 10

Referring now to FIGS. 22-24 , a tray 2200 is illustrated for use withthe wrench 10 of any embodiment of the present invention. The tray 2200includes an enclosure 2202 within which the wrench 10 or other tool canbe initially packaged, along with other suitable attachments or devices(not shown) for use with the wrench 10. The enclosure 2202 also houses acalibration device 2204 therein. The device 2204 includes a connectorport 2206 for engagement with the shaft 14 of the wrench 10, a number ofoperational buttons 2208 to control the operation of the device 2204,and a display 2210 for providing a visual representation of the outputof the device 2204 to the user. The connector 2206 is operably connectedto a torque-measuring device 2212 disposed within the device 2204, andcapable of determining the torque applied to the connector port 2206 bythe wrench 10, and providing an output of the torque value determinedvia the display 2210. By engaging the wrench 10 with the device 2204 andmeasuring the torque applied by the wrench 10 on the wrench 10 and onthe device 2204, it is possible to determine if the wrench 10 needs anyadjustment in order to have the torque level measured by the wrench 10match the level measured by the device 2204. The tray 2200 can also beformed without the device 2204 and simply used as an easy to assemblereceptacle for holding each of the items, including the tool or wrench10, forming the kit to be in any given procedure or process.

In other alternative embodiments, the battery assembly/power source 19for the wrench 10 of any embodiment of the present invention can beformed to be removable as a unit from the body 12 of the wrench 10similarly to the embodiment in FIG. 7 . The battery assembly/powersource 19 is initially formed as a sterile component that can be securedto or within the body 12 of the wrench 10 to supply power thereto, andoptionally to form a part of the barrier 33 or that can be separate fromthe barrier 33. In circumstances where the wrench 10 is dropped or wherethe wrench 10 is stored for a significant period of time, the powersource 19 can be removed from the wrench 10 and the wrench 10 can beautoclaved. A new, sterile power source 19 can then be engaged with thewrench 10 to provide power to the wrench 10.

Looking now at FIG. 25 , a ninth embodiment of the electronic drivingdevice 2000 is illustrated. In this embodiment, the device or tool 2000includes a body or cradle 2002 and a power pack/sensor module 2004. Thecradle 2002 is shaped as desired to provide an effective grippingsurface for an individual utilizing the tool 2000, and can be formed tohave any desired configuration or designs thereon. In the embodiment ofFIGS. 25-27 , the body or cradle 2002 has a sleeve-like shape withapertures 2006 and 2008 disposed generally opposite one another. Thepower pack/sensor module 2004 includes a housing 2010 shapedcomplementary to the shape of the cradle 2002, and has a sleeve 2011extending outwardly from the housing 2010 that is operably connected toa electronics unit/torque sensing mechanism 2014 within the housing 2010and adapted to receive and engage an adapter 28, 2052 and/or animplement shaft 2038 for engagement with and driving of a fastener (notshown). The housing 2010 is configured to be slidable or otherwisemovable with respect to the cradle 2002 such that the housing 2010 canbe inserted within the cradle 2002 by inserting the housing 2010 throughthe aperture 2006 and pushing the housing 2010 through the cradle 2002until reaching the opposite end of the aperture 2008. In this position,the visual torque indicators 2012 on the housing 2010 that are operableby an internal power source (not shown) in response to the torque sensedby the torque sensing mechanism 2014 within the housing 2010 are visiblethrough the aperture 2006 and/or 2008.

The following are certain features of the illustrated embodiment of thetool 2000:

-   -   Accuracy of measurement of torque by sensing mechanism 2014 is        +1%    -   In one embodiment of the sensing mechanism 2014, the solid state        sensor does not rely on mechanical friction, thereby increasing        accuracy    -   The indicators 2012 in one embodiment are formed as LEDs that        are operated sequentially and/or cumulatively to provide visual        signals when approaching a torque limit, thus reducing the        chance of over torque.    -   Other indicators, such as a vibrating motor (not shown) disposed        within the housing 2010, and green LED 2012 will notify surgeon        that torque set point has been reached.    -   Other indicators, such as an audible buzzer, and a red LED 2012        activate to signal over torque.    -   The torque sensing mechanism 2014 of the tool 2000 can be        calibrated to five (5) set torque points and the user can be        notified that the torque set point has been reached by        illuminating lights 2012, activating the buzzer or a vibrating        motor or a combination thereof.    -   The above feedback devices 2012 can also be made to pulse on and        off at a varying frequencies. This pulsing would also conserve        battery power.    -   The housing 2010 can include a light (not shown) to shine        through the cradle 2002 or an aperture 2006, 2008 onto the site        where the tool 2000 is being applied.    -   The light weight design of the cradle 2002 and the housing 2010        of suitable materials, such as selected plastics and metals, is        lighter than mechanical torque handles thereby reducing user        fatigue.    -   The sensor module 2004 provides for a custom programmable torque        set point and tolerance band to suit implant design.

The following are some of the advantages of single use design for powerpack/sensor module 2004 use with the tool 2000:

-   -   The sensor module 2004 provided for use is in a certified        factory calibrated condition.    -   The cost for the tool 2000 in a procedure tray 2200 is        significantly lower since the majority of the cost is in the        disposable sensor module 2004 which is a single use item billed        to the surgical procedure.    -   The reusable cradle 2002 is of simple construction, such as of a        suitable plastic or metal, and therefore easy to clean and        sterilize.    -   The tool 2000 takes up less room in the procedure tray 2200 and        takes weight out of the tray 2200 hence lighter and easier to        sterilize the components of the procedure tray 2200.    -   The construction of the tool 2000 allows two tools 2000 to be        disposed in the procedure tray 2200 to provide redundancy for        the tray while still providing a lighter and lower cost tray        than a procedure tray 2200 carrying one mechanical reusable        handle.    -   The tool 2000 eliminates the need for recalibration or        maintenance programs, facilities and personnel, as the power        pack/sensor module 2004 is pre-calibrated for the single use,        and then disposed of.

FIGS. 28A-28B show another embodiment of the tool 2000. In thisembodiment, the cradle 2002 and the power pack/sensor module 2004 areformed such that the power pack 2004 is inserted into the cradle 2002 ina top loading fashion, with the sleeve or stem 2011 extending through acentral opening 2013 in the cradle 2002. FIGS. 29A-29B show anotherembodiment of the tool 2000 in which the cradle 2002 is formed with asingle aperture 2006 at one end, such that the power pack 2004 isinserted into the cradle 2002 in a side loading fashion, with the stem2011 extending through a slot (not shown) formed in the cradle 2002.

Looking now at FIGS. 30-35 , another embodiment of the tool 2000 isshown in which the cradle 2002 includes locking device 2300 used to holdthe module 2004 in the cradle 2002. In the illustrated embodiment, thelocking mechanism 2300 includes a number, and preferably a pair ofopposed recesses 2016 in the cradle 2002 that are engaged by a lockingmember 2018 disposed on the housing 2010. The locking member 2018includes a casing 2020 disposed within the housing 2010 and extendingoutwardly from opposed sides thereof. The casing 2020 includes a pair ofbores 2022 at each end within each of which are disposed a spring 2024and a detent 2026. The detent 2026 is retained within the bore 2022 byan inwardly extending rim 2027 formed at the outer end of the bore 2022,where the rim has a diameter less than that of the detent 2026. Thedetents 2026 are urged out of the bores 2022 by the springs 2024. Whenthe housing 2010 is positioned within the cradle 2002, the sides of thecradle 2002 initially press the detents 2026 into the bores 2022 againstthe bias of the springs 2024. When the detents 2026 reach the recesses2016, the springs 2024 urge the detents outwardly into the recesses 2016to secure the housing 2010 to the cradle 2002. Removing the housing 2010from the cradle 2002 requires a sufficient force be applied to housing2010 to urge the detents 2026 back into the bores 2022 against the biasof the springs 2024. The force exerted by the springs 2024 is such thatthe housing 2010 will not be inadvertently removed from the cradle 2002during the normal operation of the tool 2000.

Referring now to FIG. 36 , the tool 2000 is shown with a lockoutmechanism 2028 disposed therein. The mechanism 2028 includes a lock outswitch 2030 disposed within the housing 2010 and operably connected to acircuit board 2034 located in the housing and forming the torque sensingmechanism or system 2014, which in this or any other embodiment for thewrench can be any type of conventional electronic torque sensingmechanism. When the housing 2010 is positioned within the cradle 2002,the switch 2030 is positioned over the magnet 2032 held in the cradle2002, which activates the switch 2030 to enable the power pack/sensormodule 2004 to become operable.

This embodiment in FIG. 36 also illustrates how the torque sensingmechanism 2014 includes sensors 2036 operably connected to the board2034 and to the sleeve 2011 in order to sense the torque applied by thetool 2000 via an implement 2038 operably connected to the sleeve 2011,such as via an adapter 2052 secured to the cradle 2002 and engaged bythe sleeve 2011 when inserted through the cradle 2002.

Looking now at FIG. 37 , another embodiment of the tool 2000 includes ahousing 2010 having an electronic lock out switch 2040 operablyconnected to the board 2034 that is positioned over a post 2042 on thecradle 2002 when the housing 2010 is engaged with the cradle 2002. Thepost 2042 contacts or otherwise operably connects with the switch 2040to operate the switch and active the power supply of the powerpack/sensor module 2004. This can be accompanied by an active powerlight (not shown) that is visible on the housing 2010 or on the cradle2002 when the post 2042 engages the switch 2040.

Referring now to FIGS. 38 and 39 , the tool 2000 includes a ratchetingmechanism 2044, which can be disposed within an adapter 2052 secured tothe cradle 2002 and used to secure the shaft 2038 to the cradle 2002,secured to the sleeve 2011 and through which the implement shaft 2038extends into connection with the sleeve 2011. The ratchet mechanism 2044can be any suitable mechanism, such as that disclosed in U.S. Pat. No.6,817,458, which is expressly incorporated by reference herein in itsentirety, allows the implement 2038 to be moved in a stepwise,ratcheting manner, with each step provided with an indication of thetorque exerted by the tool 2000 via the torque sensing mechanism 2014.

In a different configuration for the attachment of a ratchetingmechanism 2044 to the tool 2000, in FIG. 39 the sleeve 2011 includes amember 2046 having external splines 2048 thereon. The splines 2046 arematable with internal splines 2050 formed on a ratchet gear 2051disposed within the adapter or connector 2052, which can be a quickrelease adapter. When there is a ratchet assembly or mechanism 2044disposed in the housing for the adapter 2052, the ratchet gear is oftenlocked in a forward or reverse position. If one is trying to assemblethe power pack 2004 into the cradle 2002 that has a ratchet assembly2044, the shaft or sleeve 2011 of the power pack 2004 has to mate withthe ratchet gear 2051 to transmit torque. In order for the mating totake place the ratchet gear 2051 could be rotated until it fits/mateswith the shaft 2011. However if the ratchet gear 2051 is in a lockedposition it cannot be rotated or in a ratchet position it can only berotated on one direction clockwise (CW) or counter clockwise (CCW).Having a tapered splined shaft member 2046 on the mating end of theshaft 2011 allows the shaft 2011 to easily mate with the ratchet gear2051 with internal tapered splines 2050 without rotating the ratchetgear 2051 or unlocking it. The more splines 2048 on the shaft 2011, theless the shaft 2011 needs to rotate and therefore the smoother themating between the shaft 2011 and gear 2051, such that the power pack2004 and the ratchet assembly 2044 can be mated without having to switchthe ratchet gear position, i.e. the large number of splines 2048, 2050allows the power pack 2004 to be assembled to the gear 2051 with minimalrotation while the gear 2051 is in a locked position.

In still another configuration shown in FIGS. 40-42 , anotherembodiment, the power pack 2004 can be inserted into the cradle 2002with the sleeve 2011 of the housing passing through the cradle 2002 forengagement with a locking collar 3000 disposed on the ratchetingmechanism 2044. The collar 3000 is rotatably mounted on the ratchetingmechanism 2044 and has an adapter 3002 therein. The adapter 3002 definesa blind bore 3004 within which the sleeve 2011 is inserted to engage thecradle 2002 and the housing 2010 with the collar 3000 and mechanism2044. The closed end of the adapter 3002 includes a projection 3006having a number of teeth 3008 thereon that engaged with the internalgear of the ratcheting mechanism 2044. Thus, when the sleeve 2011 isinserted within the adapter 3002, the twisting of the housing 2010 andcradle 2002, which forms the handle for the tool 2000, correspondinglymoves the ratcheting mechanism 2044, and the torque applied to themechanism 2044 any shaft 2038 attached thereto, is effectivelytransmitted to the module 2004 for measurement and display.

The sleeve 2011 is held within the adapter 3002 by the engagement of thecollar 3000 between the mechanism 2044 and the sleeve 2011. In theillustrated embodiment, the sleeve 2011 includes a post 3010 extendingoutwardly from the sleeve 2011. The post 3012 is insertable within achannel 3010 formed in the collar 3000. A locking member 3014 isdisposed within the collar 3000 and can be selectively engaged with thepost 3012 in order to securely engage the post 3012 and the sleeve 2011with the collar 3000. The locking member 3014 can be disengaged from thepost 3012 to enable the sleeve 2011 to be withdrawn from the adapter3002.

Looking now at FIGS. 43-45 , in another embodiment for the tool 2000,the cradle 2002 is formed with the mechanism 2044 fixed to the cradle2002 by a connecting shaft 3016. The sensor module/power pack 2004 issubsequently inserted into the cradle 2002 and connected to theconnecting shaft 3016. In FIG. 44 , the connection between theconnecting shaft 3016 and the cradle 2002 is made by a locking pin 3018on the shaft 3916 that is engaged within a pair of opposed notches 3020disposed in the cradle 2002.

In this embodiment, as best shown in FIG. 45 , the maximum torque thatcan be applied by the tool 2000 is limited by the a torque limitingmechanism 3022, such as that disclosed in U.S. Pat. No. 7,806,026, whichis expressly incorporated by reference herein in its entirety. Inaddition, the locking pin 3018 and/or the connecting shaft 3016 caninclude notched sections 3024 therein. The size of these notches 3024 isselected to enable the shaft 3016 and/or pin 3018 to have a shearstrength equal or approximately equal to the maximum torque to beapplied by the tool 2000. Thus, when this torque level is reached, theshaft 3016 and/or pin 3018 will shear at the notch 3024, rendering thetool 2000 inoperable and incapable of applying further torque.

FIGS. 46A-46F show other alternative configurations for the housing 2010and the corresponding insertion/engagement of the housing 2010 in thecradle 2002.

Looking now at FIGS. 47A-47D, the tool 2000 is illustrated in which thehousing 2010 and stem 2011 for the power pack/sensor module 2004 areconfigured in a manner that enables the same module 2004 to be used withcradles 2002 having different configurations. In FIG. 47A the housing2010 has an implement shaft 2038 secured to the stem 2011, and thehousing 2010 and shaft 2038 combination are engaged with the cradle 2002by first inserting the shaft 2038 through the opening 2013 in the cradle2002. In FIG. 47B, the shaft 2038 is secured to the cradle 2002, withthe housing 2010 subsequently engaged with the cradle 2002 and the shaft2038. In FIG. 47C, the cradle 2002 includes an adapter 2052 secured tothe cradle 2002, and which can be used to releasably connect the shaft2038 to the cradle 2002. In FIG. 47D, the cradle 2002 includes anadapter 2052 having a ratchet mechanism 2044 therein.

With these configurations for the tool 2000, the sensor pack 2004 is asingle use item and the cradle 2002 is the reusable item as it can besterilized. Some customers may want a device with a fixed shaft (A) inwhich case the cradle 2002 is very small and light and possibly theleast costly. Since the cradle 2002 is in the instrument tray kit 2200,the overall instrument tray kit cost is lower.

The sensor packs 2004 used in options B, C and D are identical to eachother and the only difference to option A is that the entire length ofthe shaft 2038 is attached to the sensor pack 2004.

Having identical configurations for the sensor pack 2004 allows the enduser to buy and stock one sensor pack 2004 and still use it on any ofthe three different cradle options 2002. From the manufacturers viewpoint having an almost identical sensor pack 2004 construction acrossoptions A-D allows for higher volumes and hence lower items costs.

B: this option allows the end user to buy a lower cost sensor pack 2004which is a single use item since a sensor pack 2004 with a shorter shaftis less costly to manufacture and ship.

C: this options allow the end user to use any shaft 2038 that hasappropriate mating features with the tool 2000 (sensor pack 2004+cradle2002). End user may use multiple shafts 2038 custom to each implant oracross various implants.

D: this option allows the end user to use any shaft 2038 and have theability to ratchet the device to appropriately position the tool 2000for ease of use.

Further, in FIG. 48 , one configuration for a connector 8000 forsecuring the pack 2004 to the cradle 2002 and shaft 2038 that utilizes alocking ring 8002 and a fixed ring 8004, each having bores 8006 thereinwithin which are placed opposed ends of spring pins 8008 to control themovement of the rings 8002 and 8004 with respect to one another.

In another embodiment of the tool 4000 shown in FIG. 49 , in order toprovide an alternative safety aspect to the tool 4000, the cradle 4002includes a mechanical torque-limiting mechanism 4100 disposed within thecradle 4002 and engaged at one end with the shaft 4038 and at the otherend with the stem 4011 on the housing 4010 of the sensor pack 4004 tooperably connect the torque sensing device 4014 in the sensor pack 4004with the shaft 4038 to measure the torque applied by the tool 4000. Thetorque-limiting mechanism 4100 can be any suitable mechanism, such asthat disclosed in U.S. Pat. No. 7,650,821, which is expresslyincorporated by reference herein in its entirety. In the event that thesensor pack 4004 malfunctions and does not provide accurate indicationsto the used of the torque being applied by the user through the tool4000, the torque-limiting mechanism 4100 will operate in a mechanicalmanner to prevent excessive torque from being applied by the tool 4000.

In addition, in conjunction with the mechanism 4100, the tool 4000 caninclude an indicator 4102 operably connected to the mechanism 4100 thatprovides an indication to the user of the tool 4000 that the mechanism4100 has exceeded its torque limit. One example of such a mechanism 4102is disclosed in U.S. Pat. No. 7,806,026, previously incorporated byreference herein in its entirety.

Further, the tool 4000 can include a variable gear ratio drive mechanism4104, such as that disclosed in U.S. Patent Application Publication No.US2010/0294084, which is expressly incorporated by reference herein inits entirety.

In FIGS. 50 and 51 , embodiments of the tool 2000 are shown in which thesensor module 2004 is operably connected to a video screen 18000 that andisplay the torque values sensed by the module 2004, or that includes adisplay 18002 on the module 2004 capable of displaying the sensed torquevalues, and also functioning as a video screen to display the site onwhich the individual is using the tool 2000. In the illustratedembodiments, FIG. 50 shows a tool 2000 connected wirelessly to thedisplay 18000, while FIG. 51 shows a display 18002 disposed directly inthe tool 2000.

Looking now at FIGS. 52-54 , a twenty first embodiment of the tool 5000is illustrated in which the tool 5000 includes, among other featuresshown in prior embodiments such as an adapter 5028 and a ratchetingmechanism 5044, among others, a receiver coil 5002 disposed within aportion of the handle 5004 for the tool 5000 and operably connected tothe other electronic components in the tool 5000, such as a battery pack5005 and torque measuring mechanism (not shown) and display (not shown).The receiver coil 5002 is able to be positioned in electrical contactwith a transmitter coil 5006 disposed on a charging station 5008 inorder to provide a wireless, inductive charge through the receiver coil5002 to the battery pack. The station 5008 includes features to properlyalign and maintain the alignment of the tool 5000 and receiver coil 5002with the transmitter coil 5006 on the station 5008, to ensure a propercharge when the tool 5000 is positioned on the station 5008.Additionally, the station 5008 includes a power cord 5014 that enablesthe station 5008 to be supplied with power via any conventional poweroutlet, such as a wall outlet (not shown). The station 5008 can alsoinclude a display 5010 that provides various information on the statusof the station 5008 and of the tool 5000 placed on the station,including, but not limited to the status of the charging of the tool5000 on the station 5008, which can be altered by using selector buttons5012 on the station 5008. Some advantages of this construction for thetool 5000 include:

-   -   1. Wireless battery charging allows a rechargeable battery to be        sealed in the device 5000. This way the battery is sterilized        within the device 5000. This eliminates the need to handle a        battery pack and load the battery pack into the device while        using aseptic techniques. Therefore improved safety for the        patient. Since the charging is wireless both the charger 5008        and the device 5000 do not need exposed metal contacts and thus        can be sealed which makes them safer to use and clean/sterilize        for use in an operating room environment which often involves        exposure to moisture especially during the cleaning process,        such as steam cleaning/autoclaving.    -   2. Principle of operation: Power is transmitted by inductive        coupling. The system involves two devices, the battery powered        device 5000 and the wireless charger 5008. The charger 5008 has        a transmitting coil 5006 which transmits power to the receiver        coil 5002 which is located in the device 5000 when the receiver        coil 5002 is placed in the magnetic field created by the        transmitting coil 5006 by inductive coupling. The receiver coil        5002 is connected to a rechargeable battery. This battery        supplies power to the circuit within the handle 5004. The        transmitter and receiver coils transmit power using high        frequencies (radio frequencies) this power charges up the        battery. The two coils are tuned to each other to make this        energy transfer possible. The closer together these coils are        placed and the better they are aligned the more efficient the        power transfer will be. Image shows the device placed near the        coil in the charger. A custom fitted stand could be designed for        best alignment or a more generic mat type charger could be used        to charge multiple devices at once. Related patents for wireless        power transmission include U.S. Pat. Nos. 3,938,018; 5,314,453;        5,314,457 and 8,378,523, each of which are expressly        incorporated by reference herein in their entireties.

Referring now to FIGS. 55-57 , in order to enable the use of prior artrechargeable non-sterile batteries in sterile surgical instruments ortools 10, 2000, 6000, as described in U.S. Pat. No. 6,917,183, which isexpressly incorporated by reference herein in its entirety, users employa known “sterile transfer” technique. While possibly known by othernames, this technique generally entails the sterilization and use of asterile battery container to be attached to a sterile poweredinstrument. The sterilized container is held in a sterile field (by ascrub nurse, for example) and is shielded by a sterile shroud. Anon-sterile, charged battery (held by a circulating nurse, for example)is placed into the sterilized container with care so as not tocontaminate the already sterilized container. The shroud is then removedby the circulating nurse and the sterilized container is closed by thescrub nurse and attached to the instrument. The container hermeticallyencloses the battery and has its own exterior terminals which areconnected to the battery terminals and through which the instrument ispowered.

The battery used is generally a battery pack comprising a plurality ofindividual battery cells wired and bound together in one unit. Theterminals of the cells are connected in series and to the terminals ofthe battery pack. As used herein, the term “battery” will be understoodto include a battery pack.

Prior art battery packs generally have terminal contacts which aresurface mounted and engageable by contiguous engagement with anothersurface contact in the device with which the battery pack is designed tooperate. The surface contacts are designed to be pressed toward eachother, essentially pushing in opposite directions along an imaginaryline passing through both contacts at the point at which they arecontiguous. Sometimes a spring force is designed into the engagement toenhance the force with which the terminal contacts press against thedevice contacts.

Surface contacts are subject to vibration in powered surgicalinstruments and this may increase wear and affect performance. Also,surface contacts may subject a battery to risk of shorting if thebattery terminals inadvertently connect conductive materials beforebeing put into the intended instrument.

Additionally, surface contacts necessarily increase the size of thebattery and/or battery/instrument combination. This occurs simplybecause of the necessity of providing relatively massive contacts and/orspring mechanisms to maintain a secure connection during use. Further,the battery packs that are sealed to be steam sterilized to addressthese concerns would necessarily lose a lot a significant portion of thestored charge when heated up to sterilization temperatures which are ashigh as 134° C. (273.2° F.).

To address these concerns and shortcomings of prior art rechargeablebattery packs that cannot survive the harsh environment of steamsterilization in an autoclave, and since steam sterilization is the mostcommonly used method for sterilizing instruments, a twenty-secondembodiment of the tool 6000 shown in FIGS. 55-57 and 60-64 isconstructed with three sub-assemblies, namely, a handle base or cradle6002, which can include attributes of the prior embodiments, such as anadapter, a ratcheting mechanism, torque-limiting mechanism, lightingassembly, etc., a sensor pack 6004 engageable with the handle 6002, anda replaceable and rechargeable battery pack 6006 engaged with the handle6002 and sensor pack 6004. Each sub-assembly has a different “lifeexpectancy” in the harsh environment of steam sterilization. In oneembodiment:

-   -   1. Part 1—HANDLE BASE 6002 with quick connect collet/adapter        6028 and ratcheting mechanism 6044; this is reusable and steam        sterilizable up to at least 150 autoclaves.    -   2. Part 2—SENSOR PACK 6004 (contains electronics making up        electronic torque sensing mechanism 6014, electronics unit 6020        and display 6022, and can be fixed or releasably connected to        the base 6002)—reusable up to approx. 100 autoclaves    -   3. Part 3—BATTERY PACK 6006 can also, in certain embodiments,        contains the buzzer and vibrating motor (not shown) in addition        to the battery pack and connector—is designed for a single use.        Battery pack 6006 is sterilized by EtO and is sold sterile in a        sealed pouch and is not intended for steam sterilization. Each        component has benefits making the surgical procedure safer,        simpler and reducing patient risk and improving outcomes. The        main area of risk is in the cleaning and sterilization. By using        a sealed and EtO sterilized battery pack the user is sure to        receive a fully charged battery pack. If the procedure lasts too        long they can open a fresh battery pack.    -   4. Part 4—STERILE INSERTION SHIELD 6040 can also optionally be        utilized with non-sterilized battery packs 6006′ in a second        embodiment shown in FIGS. 60-64 .

The single use battery pack 6006 has many advantages over a rechargeablebattery, including:

-   -   1. If the device 6000 is dropped on the floor during a surgery        the surgeon can dispose of the non-sterile battery pack 6006,        the surgical staff can clean and flash sterilize the device 6000        within minutes and load a new sterile battery pack 6006 thereby        avoiding the wait for a battery to be recharged. Another benefit        is that no battery charger is required.    -   2. The battery pack 6006 is sterilized and sold sterile in a        sealed pouch so the risk of infection from an improperly cleaned        rechargeable battery is reduced.    -   3. In an alternative embodiment where the single use battery        pack 6006′ is not sterilized prior to use, best shown in FIGS.        60-64 , the battery pack 6006′ is designed not to be steam        sterilizable, resulting in a smaller volume and lighter battery        pack 6006′ than required for steam sterilizeable battery packs        6006, since steam sterilizeable battery packs 6006 typically        have the additional mass of heat shielding materials to        encapsulate the batteries and more than necessary chemical mass        to compensate for the amount of charge lost due to the high        temperatures of steam sterilization (250-275° F.). Additionally,        non-sterile battery packs 6006′ last much longer than        sterilizeable battery packs 6006 because they do not repeatedly        undergo the extreme conditions of steam sterilization, and do        not have the battery and/or other electronics disposed within        the battery pack 6006′ potentially damaged by the sterilization        process. Further, non-sterilizeable battery packs 6006′ can be        safer to use since they are not exposed to high heat and        therefore less chance of explosion.

The device 6000 in this embodiment also has electronics (not shown)therein, e.g., in the handle 6002, the sensor pack 6004 or the batterypack 6006, that will count the number of times the device 6000 waspowered on, alone or in conjunction with other electronics within thedevice 6000, and can notify the user of device life left and when toreplace the sensor pack 6004.

In another embodiment, the device 6000 can have electronics (not shown)therein, e.g., in the handle 6002, the sensor pack 6004 or the batterypack 6006, that will count the number of times the device 6000 wasautoclaved, alone or in conjunction with other electronics within thedevice 6000, and can notify the user of device life left and when toreplace the sensor pack 6004.

When a non-sterilizable battery pack 6006′ is utilized, the aseptictransfer process for using this type of battery pack 6006′ is shown inFIGS. 60-64 . Initially, in FIG. 60 , the sterile handle 6002 or sensorpack 6004 of the device 6000 is opened by an individual I in the sterilefield to expose the chamber 6042 in which the battery pack 6006′ is tobe positioned. In the open position, the chamber 6042 can be engaged bythe individual I in the sterile field with a sterile shield 6040 (FIG.61 ) that includes a sleeve 6044 that is releasably engageable withinthe chamber 6040 and a number of shielding surfaces 6046, 6048surrounding and/or extending outwardly from the sleeve 6044. Thesurfaces 6046, 6048 allow access to the chamber 6042 through the sleeve6044 while preventing direct contact with the chamber 6042 or any othersurface of the device 6000. In FIG. 62 the shield 6040 is illustratedwith the sleeve 6044 partially engaged within the chamber 6042 to enablethe chamber 6042 to be exposed while also protecting the remainingsurfaces of the handle 6002, sensor pack 6004 and device 6000 using thesurfaces 6046, 6048. In FIG. 63 , an individual O outside of the sterilefiled then inserts a non-sterile battery pack 6006′ into the chamber6042 through the sleeve 6044 of the shield 6040, while preventing thenon-sterile individual from contacting the sterile device 6000. Once thenon-sterile battery pack 6006′ is fully inserted within the chamber6042, the sleeve 6044 of the shield 6040 can be removed from around thebattery pack 6006′ by the individual outside the sterile field, and theindividual in the sterile field can close the handle 6002 withoutcontacting the battery pack 6006′ and activate the device 6000 includingthe non-sterile battery pack 6006′.

Looking now at FIGS. 58-59E, in a twenty-third embodiment of the device7000, the device 7000 can include any features of any prior embodiment,and as illustrated includes a display 7002 and includes a suitabletransceiver (not shown) configured to transmit and/or receiveinformation using a suitable protocol (NFC, RFID, Bluetooth, etc.) froma separate electronic computing device 7004, such as a desktop computer,laptop computer, or tablet computing device, among others that can alsoinclude a display 7006. The communication between the device 7000 andthe computing device 7004 enables the torques being applied by thedevice 7000 to be transmitted and stored in the device 7004, or in asuitable electronic data storage medium or location operably connectedto the device 7004.

In one embodiment, the recording feature for the electronic torquewrench 7000 can transmit data wirelessly to an app on the device 7004.The app (“App” is an abbreviation for application; “App” definition: Anapp is a piece of software. It can run on the internet, on a computer,on a phone or other electronic device.) can run on a device 7004 withany suitable operating system, such as an android or iOS device. Theprocedure would involve the initial step where the doctor opens the appon the device 7004 which would show the image of the entire constructbeing implanted in the procedure. The electronic torque wrench 7000would subsequently be set to transmit mode. The surgeon could even takethis image of the construct during surgery. Now the surgeon would touchthe screen image of the fastener on the display 7006 of the device 7004he/she is about to tighten, the app would then present the appropriatetorque values for the tightening the fastener, upload the values to thedevice 7000 for use by the surgeon tightening the particular fastener.Now the surgeon would proceed with using the ETW 7000 to tighten thefastener on the construct, and the device 7004 would record the torquevalues that are being transmitted by the device 7000 to be saved on thedevice 7004 or similar smart electronic device with a link that appearsin the pixel grid location that the surgeon tapped. The surgeon thentouches the next fastener he/she is about to tighten then tightens andfastener and so on, and in one embodiment performs this function using apredetermined sequence for tightening the fasteners provided by theinformation displayed on the device 7004.

Data retrieval: When retrieving the data from the device 7004, theperson retrieving the data would be able to play each torque data fileby touch the links provided in the each pixel location on the screenimage.

In this embodiment, NFC (Near Field Communication) or RFID(Radio-frequency identification) can be used to establish a connectionbetween the ETW 7000 and the electronic device 7004, like a mobile phoneor ipad. For higher data transfer rates, a wireless connection likeBluetooth can be used which is capable of higher data transmissionrates. The ETW device 7000 could be coupled to other electronics devices(not shown) like monitors to display live streaming torque data orreplay recorded data.

As shown in FIGS. 59A-59E, the ETW 7000 could have a screen 7002 withbuttons or no screen and buttons. In the case of no buttons and screenthe ETW 7000 could be controlled and even activated by the presence ofthe compatible RFID, NFC or Bluetooth capable or similar devices. Thisdata includes downloading data recorded on the ETW 7000 or playing avideo of the data being recorded on the NFC app.

Since NFC is a very simple way to establish a link between two devicesthis could be used to establish the link while Bluetooth connections canbe used to transfer data between the two devices. Examples of this areNokia and Sony that use NFC to pair Bluetooth headsets and speakers witha tap in a NFC device.

Patient data security is inherent in the type of communication being‘near field’ which is currently 4 to 10 cm. Another way to add securityis for security codes to also be programmed into the NFC tags (unpowered NFC chip is called a tag) on the two communicating devices. Thiscould be monitored by a microcontroller which looks for and checks thesecurity codes on both devices before allowing the communication toproceed between them.

RFID tags used with the device 7000 can be either active or passive.RFID communication between two devices can be of the following types.

Passive Reader Active Tag (PRAT)

Active Reader Passive Tag (ARPT)

Active Reader Active Tag (ARAT)

With regard to the utility of the tool/device 7000, the following aresome reasons for the usefulness of this embodiment of the device 7000,and some descriptions of alternative embodiments of a system 7010employing the devices 7000 and 7004.

-   -   It assures the surgeon that the correct torque was applied.    -   In an investigation a record of correctly torqued fasteners        would help vindicate the surgeon, hospital and the implant OEM.    -   In a case where there are complications a more precise torque        instrument will mean there is one less chance of error that the        surgeons need to be concerned with.    -   More accuracy may also be important in cases that may start out        simple but become complicated.    -   A more precise torque wrench on the market could lead to OEMs        designing new implants that need this higher precision.    -   This higher precision could be desired on surgeries like        cochlear implantations that require very low precise torques.        Additionally not having a sharp jarring from a torque limiting        mechanism may be desirable in delicate surgeries.    -   A wireless display would allow the surgeon to see the torque        value on the video screens along with real time surgical video        and other vital patient information. They would not have to move        their eyes from the video screen to the torque handle. The        surgeon would only look at an indicator wrench, they would not        look at a torque limiting wrench. The surgeon would not use a        torque if they were using a break-away driver with a type of        screw in which the head breaks off when the appropriate torque        is met or exceeded.

The device 7000 can also include a recording/memory storage functionthat allows the surgeon to record the values of the torque applied toeach fastener. The benefit of this feature is that the surgeon wouldhave proof of the torque applied to each fastener in case a fastener, arod or some other part of the construct became loose and there was aquestion of whether the correct torque was applied during the procedure.

Concept #1 for the recording feature: the surgeon would use a suitableportable computing device, such as a tablet computer or similar touchscreen device 7004 with the image of each fastener superimposed over theimage of the anatomy, then the surgeon could

-   -   touch the fastener on the tablet device 7004    -   then push the record button on the torque meter for the device        7000 and then tighten the fastener.

The device 7000 would then record the peak torque value and transmit thevalue to the device 7004 where the software would tie the image of thefastener to the torque value recorded.

Concept #2 for the recording feature: the device 7000 would havenavigation orbs (not shown) attached to it which would communicate itslocation to the navigation software on the device 7000 or 7004.

When a record button (not shown) on the device 7000 is activated, thedevice 7000 records the torque value and the location coordinates of theapplied torque. The navigation software then keeps this torque recordalong with images of the construct which ties the fastener location tothe torque value recorded.

While the concepts of the present disclosure will be illustrated anddescribed in detail in the drawings and description, such anillustration and description is to be considered as exemplary and notrestrictive in character, it being understood that only the illustrativeembodiments are shown and described and that all changes andmodifications that come within the spirit of the disclosure are desiredto be protected. There are a plurality of advantages that may beinferred from the present disclosure arising from the various featuresof the apparatus, systems, and methods described herein. It will benoted that alternative embodiments of each of the apparatus, systems,and methods of the present disclosure may not include all of thefeatures described yet still benefit from at least some of the inferredadvantages of such features disclosed in other embodiments which aredeemed to be included in the disclosures of each of the variousembodiments disclosed herein. Those of ordinary skill in the art mayreadily devise their own implementations of an apparatus, system, andmethod that incorporate one or more of the features of the presentdisclosure and fall within the spirit and scope of the disclosure asdefined by the appended claims.

The invention claimed is:
 1. A surgical tool comprising: a. a bodyincluding a fastener engaging shaft attached thereto; the shaftextending outwardly perpendicularly from the body; b. a display disposedwithin the body; and c. an electronics unit insertable within the bodyseparate from but operably connectable to the display, the electronicsunit capable of: i. measuring an operating parameter of the tool duringapplication of the operating parameter using the tool to determine ameasured operating parameter; ii. storing the measured operatingparameter within the electronic unit in the tool; and iii. providingaccess to the stored measured operating parameter within the electronicsunit when queried by the user; the tool capable of being used formultiple surgical procedures.
 2. A surgical tool comprising: a. a body;b. a display disposed within the body; and c. an electronics unitinsertable within the body separate from but operably connectable to thedisplay, the electronics unit capable of: i. measuring an operatingparameter of the tool during application of the operating parameterusing the tool to determine a measured operating parameter when the toolis employed in a surgical procedure; ii. storing the measured operatingparameter within the electronic unit in the tool during the surgicalprocedure; and iii. providing access to the stored measured operatingparameter within the electronics unit when queried by the user; the tooldesignated as a single use tool.
 3. A surgical tool comprising: a. abody; b. an electronics unit removably insertable within a sterilizationbarrier formed within the body, the electronics unit capable of: i.measuring an operating parameter of the tool during application of theoperating parameter using the tool to determine a measured operatingparameter when the tool is employed in a surgical procedure; ii. storingthe measured operating parameter within the electronic unit in the toolduring the surgical procedure for comparison with stored optimalmeasured parameters associated with the surgical procedure; and iii.providing access to the stored measured operating parameter within theelectronics unit when queried by the user; the tool capable of beingused for multiple surgical procedures.
 4. A surgical tool comprising: a.a body; b. a display disposed within the body; and c. an electronicsunit insertable within the body separate from but operably connectableto the display, the electronics unit capable of: i. measuring anoperating parameter of the tool during application of the operatingparameter using the tool to determine a measured operating parameterwhen the tool is employed in a surgical procedure; ii. storing themeasured operating parameter within the electronic unit in the toolduring the surgical procedure; and iii. providing access to the storedmeasured operating parameter within the electronics unit when queried bythe user; the tool designated as a single use tool.